Vmac V900103 Installation guide

Brand: Vmac

Model: V900103

Type: Installation guide

This manual is also suitable for

V900093

System V900093

2007 – 2006 GM 2500HD – 3500HD

Duramax Diesel

System V900103

2010 – 2007 GM 2500HD – 3500HD

GMT900 Duramax Diesel

www.vmacair.com

VR70 UNDERHOOD

AIR COMPRESSOR

INSTALLATION MANUAL

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Installation Manual for VMAC

System V900093

2007 – 2006 GM 2500HD – 3500HD

Duramax Diesel

System V900103

2010 – 2007 GM 2500HD – 3500HD

GMT900 Duramax Diesel

General Information..................................................................... 3

Before You Start ....................................................................... 3

Special Installation Notes ......................................................... 3

Part 1: Warranty and System ID ................................................. 5

Part 2: Preparing for Installation ............................................... 8

2.1 Preparing for Installation .................................................... 8

Part 3: Installing the Control Components .............................. 15

3.1 Installing the Components .................................................. 17

3.2 Connecting the In-cab Wiring ............................................. 17

3.3 Connecting the Under-hood Wiring .................................... 19

Part 4: Installing the Tank and Hoses....................................... 21

4.1 Installing the Tank and Brackets ........................................ 21

4.2 Installing the Tank Assembly .............................................. 23

Part 5: Installing the Main Bracket and Compressor .............. 27

5.1 Installing the Cooler ............................................................ 27

5.2 Installing the Main Bracket ................................................. 28

5.3 Connecting the Hoses ........................................................ 33

5.4 Completing the Installation ................................................. 34

5.5 Adding Oil to the System .................................................... 36

Part 6: Finishing the Installation ................................................ 37

6.1 Before Starting the Engine Checklist.................................. 37

6.2 After Starting the Engine Checklist .................................... 38

6.3 Setup, Performance Testing and Adjustments ................... 39

6.5 Auxiliary Air Receiver ......................................................... 40

Accessory Products from VMAC ............................................... 41

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Installation Manual - Document #1930105

System V900093

2007 – 2006 GM 2500HD – 3500HD Duramax Diesel

System V900103

2010 – 2007 GM 2500HD – 3500HD GMT900 Duramax Diesel

Changes and Revisions

Version

Revision Details

Revised by/date

Approved

Implemented

ECN 09-081

SL 1 Oct 2009

PD 1 Oct 2009

1 Oct 2009

ECN 09-109

SL 27 Oct 2009

TG 27 Oct 2009

28 Oct 2009

ECN 10-041

SH 1 Sept 2010

SM 1 Oct 2010

6 Oct 2010

ECN 12-156

SAR 14 Nov 2012

MH 16 Nov 2012

28 Nov 2012

ECN 13-013

SH 18 Jul 2013

SC 13 Oct 2013

22 Oct 2013

Important Information

The information in this manual is intended for certified VMAC

installers who have been trained in installation procedures and for

people with mechanical trade certification who have the tools and

equipment to properly and safely perform the installation. Do not

attempt this installation if you do not have the appropriate

mechanical training, knowledge and experience.

Follow all safety precautions for underhood mechanical work. Any

grinding, bending or restructuring operations for correct fit in modified

vehicles must follow standard shop practices.

All hoses, tubes, and wires that are rerouted or shifted

during installation must be secure so that they do not

contact excessively hot areas or sharp edges. Where

possible use rubber coated P-clips. Follow the routing

suggestions in this manual and cover all hoses with the

supplied plastic loom.

These instructions are a general guide for installing this system on

standard production trucks and do not contain information for

installation on non-standard trucks. This system may not fit special

order models or those that have had other changes without

additional modifications to the truck. If you have difficulty with the

installation, contact VMAC.

All trademarks used in this manual are the property of the respective copyright holder.

The contents of this manual may not be reproduced in any form without the express written permission of VMAC,

1333 Kipp Road, Nanaimo, BC V9X 1R3.

Printed in Canada

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

General Information

Before You Start

Read this manual before attempting installation so that you can

familiarize yourself with the components and how they fit on the

vehicle. Identify variations for different model years and different

situations that are listed in the manual. Open the package, unpack

the components and identify them.

All fasteners must be torqued to specifications. Use manufacturers

torque values for OEM fasteners. Apply Loctite 242 or equivalent on

all engine-mounted fasteners. Torque values are with Loctite applied

unless otherwise specified.

STANDARD GRADE 8 NATIONAL COARSE THREAD

Size

1/4

5/16

3/8

7/16

1/2

9/16

5/8

Foot-pounds (ft-lb)

110

170

280

Newton meter (N•m)

108

149

230

379

STANDARD GRADE 8 NATIONAL FINE THREAD

Size

3/8

7/16

1/2

5/8

Foot-pounds (ft-lb)

180

320

Newton meter (N•m)

122

244

434

METRIC CLASS 10.9

Size

M10

M12

M14

M16

Foot-pounds (ft-lb)

104

174

Newton meter (N•m)

141

236

Special Tools

36 mm 12 point 1/2 inch drive socket for removing the OEM

crankshaft bolt

crankshaft locking tool (GM #J-44643) or VMAC equivalent

(Part #5900010)

VMAC crankshaft pin extraction tool (Part #5900076)

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

The following additional materials are recommended:

assorted sizes of fireproof protective plastic loom

assorted lengths of nylon tie-straps

Hose Information

Depending on other installed equipment, it might be

necessary to move the air/oil separation tank from its

intended location. The hoses used in VMAC

compressor systems have a specific inner liner that is

compatible with our compressor oil. Use of hoses other

than those supplied or recommended by VMAC may

cause compressor damage and may void your

warranty. Please contact VMAC for replacement hoses

and further information.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Part 1: Warranty and System ID

□ Complete the warranty form. The VMAC warranty form is located

at the back of this manual. This warranty form must be

completed and mailed or faxed to VMAC at the time of

installation for any subsequent warranty claim to be considered

valid.

System Identification and Operating Instructions

The System Identification Number Plate must be attached to the

vehicle at the time of installation. This plate provides information that

allows VMAC to assist in customer inquiries and the ordering of

parts.

□ Mark and drill two 7/64-inch holes in the top of the cross member

in front of the OEM air filter box. Secure the plate with supplied

self- tapping screws

□ Clean cross member beside the number plate and stick the

VMAC belt routing diagram to the cross member.

□ Apply battery warning label to driver side of primary cooling

reservoir.

□ As part of the installation process, ensure that the safety and

operational instruction decal is affixed in an obvious location so

that it can be seen by vehicle operators. A good spot for this is

usually on the inside of the door or on the panel underneath the

steering wheel. (Figure 1.1).

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Figure 1.1

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

□ To alert any technicians that may service the vehicle, affix the

servicing caution/contact label in the engine compartment near

the hood latch in a visible location. Thoroughly clean the

selected area before affixing the label (figure 1.2)

Figure 1.2

To order parts, contact your VMAC dealer. Your dealer will ask for

the VMAC serial number, part number, description and quantity. To

locate your nearest dealer, call 1-888-241-2289.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

Part 2: Preparing for Installation

2.1 Preparing for Installation

Preparation for installation is very important. Missing an item can

cause problems in the installation or even damage components.

Check off each item as it is completed.

2.1.1 V900093 Automatic Transmission Trucks

□ Locate the ECM in the engine compartment (Figure 2.1) and find

all wires that are orange with a black stripe in the bottom

connector. Use a digital voltmeter (DO NOT USE A TEST

LIGHT) to determine which wire has 0 Volts in Park/Neutral and

12 Volts in all other gear selector positions with the ignition on.

Mark the wire with a piece of tape and turn the ignition off.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

FWD

Do not connect

to the ATCM which

is mounted on the

radiator shroud on

all trucks with an

automatic transmission

Radiator

Power steering fill

ECM - under the radiator

hose between the power

steering fill and the driver

side battery. Has a black

cover

Battery

Location of tach wire

Bottom connector

orange wire with a

black stripe

FWD

Figure 2.1

2.1.2 V900103 Automatic Transmission Trucks

□ Locate the engine control module and connector ECMX2.

□ Locate the three orange wires with a black stripe. Switch the

ignition on and measure the voltage at the three wires. The

correct wire will read 0 Volts in Park/Neutral and 12 Volts in all

other gears

2.1.3 V900103 Tach Wire (CKP signal)

□ Locate the white wire with a black stripe in the top ECMX1

connector at the engine control module.

□ Start the engine and test for a constant 3 Volts at 600 RPM. If

you have a multi-meter that can measure frequency, the reading

will equal engine RPM.

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

2.1.4 V900093 Tach Wire (CKP signal)

□ For 2007 Classic: Find the white wire with the black stripe in the

top ECM connector (Figure 2.1). You can verify that you have

the correct wire by checking for a constant 3 Volts with the

engine idling at about 600 RPM. If your multi-meter can measure

frequency, the reading will equal engine rpm.

□ For 2006 Models: If there is a white wire with a black stripe in

the top ECM connector (Figure 2.1), ensure that it is the correct

wire by using the same verification process as for the 2007

Classic. Mark it with a piece of tape and turn the engine off.

If there is no white wire with a black stripe, find the three wires

that are dark blue with a white stripe in the top connector. Use

the same verification process as for the 2007 Classic to locate

the correct wire. Mark it with a piece of tape and turn the engine

off.

2.1.5 Preparing the Truck

□ Disconnect the batteries.

□ Drain the coolant.

□ Remove the top radiator hose. Measure 10 inches from the

engine end (around the curve) and mark the hose. Measure 1-

3/4 inches from the radiator end and mark the hose. Cut the

hose to length at the marks.

□ Remove the air filter assembly.

□ Remove the ATCM module from the top of the fan shroud and

remove the upper fan shroud.

□ Remove the three bolts from the fan stator, pull the fan stator

forward and unscrew the fan nut. Remove the fan and stator

together and discard the stator.

□ Remove the air intake resonator chamber from the engine.

□ Remove the OEM serpentine belt.

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Fax: 1-250-740-3201

□ Disconnect the wiring from the air conditioning compressor,

remove the four retaining bolts and move the compressor out of

the way.

Do not disconnect or damage the air conditioning lines

□ Remove the top engine coolant tube from the thermostat housing

and the top of the engine and remove the O-ring and

thermostatic switch.

□ Remove the wiring harness from the retaining clip on the driver’s

side of the engine and move it out of the way (Figure 2.2).

Figure 2.2

□ If equipped, remove the battery splitter box and ground tab

bracket from the back of the power steering pump and remove

all the power steering pump bolts. Move the pump to one side

but do not disconnect the hoses.

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Fax: 1-250-740-3201

□ If equipped, remove the ground jumper cable and the bracket

from the splitter box and secure the box and connecting harness

to the vehicle main electrical harness so that it is out of the way.

□ Remove the two 10 mm bolts and two 10 mm nuts, then remove

the OEM cast bracket that holds the air conditioning compressor

and power steering pump. Keep the bolts.

□ Remove the bolts holding the fan blades to the hub. Place the

supplied 4-1/2 inch fan spacer on the hub and install the fan

blades using the four supplied M8 bolts.

□ Remove the skid plate from under the vehicle.

2.1.3 Installing the Crankpin and Pulley

□ Install a crankshaft locking tool, remove the crank pulley bolt and

remove the crank pulley. If you are using the VMAC tool:

put the socket on the nut

put the single-pin end of the tool on the front of the pulley with

the locking tool hanging straight down

put a short extension and long flex-bar on the socket

turn the engine until the pin on the tool makes contact and the

tool jams against the protruding center-piece of the cross-

member under the front of the engine

□ Remove the crankshaft pin using the VMAC extraction tool

(Figure 2.3):

fit the split end of the tool (on the end of the shaft) over the

crankshaft pin and tap downward with the slide-hammer to

make sure that it is seated correctly

tighten the pinch bolt securely

use the hammer action of the slider in an upward motion to

remove the pin from the crankshaft

□ Install the replacement crankshaft/harmonic balancer locating pin

and tap it home using a brass drift and a small hammer. Ensure

that the head of the pin is aligned with the crankshaft by twisting

it into position with a crescent wrench (Figure 2.4).

VMAC – Vehicle Mounted Air Compressors

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Fax: 1-250-740-3201

Slide

Pinch Bolt

OEM Crank Pin

Figure 2.3

High-strength

crank pin

Figure 2.4

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Fax: 1-250-740-3201

□ Apply a light wipe of oil to the inside of the OEM crank pulley and

install the pulley back onto the crankshaft.

□ Place the VR crank pulley in position with the two roll pins on

both sides of the counter balance weight of the OEM pulley

(Figure 2.5).

□ Thread the M18 x 100 mm center bolt with OEM washer into the

crankshaft. Install an engine-locking tool and torque the center

bolt to 250 ft-lbs (340 N.m).

Position the roll pins here

Figure 2.5

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Fax: 1-250-740-3201

Part 3: Installing the Control

Components

White

Interface

Connector

Green 4 pin

connector

White Red

Red

White

Compressor

Inlet valve

Clutch

Green

Black

Black 3 pin

connector

ECM

Connect to park brake switch

Throttle

Controller

Connect to

accelerator pedal OEM Connector

from accelerator

pedal

To ground

Blue

Throttle

Controller

Blue

Connect the blue wires

MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION

Do not use short blue wire with

crimp connector

Throttle

Controller

Blue

Connect

Solder and seal to the orange wire

with the black stripe from the lower

ECM connector with O Volts in P/N

and 12 Volts in all other positions

Connect to SEO port of MBEC

Control Box

See Part for locating the correct wire

at the ECM connector

V900093 Wiring

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White

Interface

Connector

Green 4 pin

connector

White Red

Red

White

Compressor

Inlet valve

Clutch

Green

Black

Black 3 pin

connector

ECM

Throttle

Controller

Connect to

accelerator pedal OEM Connector

from accelerator

pedal

To ground

Blue

Throttle

Controller

Blue

Connect the blue wires

MANUAL TRANSMISSION

AUTOMATIC TRANSMISSION

Do not use short blue wire with

crimp connector

Throttle

Controller

Blue

Connect

Solder and seal to the orange wire

with the black stripe from the lower

ECM connector with O Volts in P/N

and 12 Volts in all other positions

Control Box

See Part for locating the correct wire

at the ECM connector

To key switched 12 Volts Fuse 10A

Connect to Park brake switch

To ground

V900103 Wiring

VMAC – Vehicle Mounted Air Compressors

Toll Free: 1-888-241-2289

Fax: 1-250-740-3201

3.1 Installing the Components

□ Install the control box where it will be accessible but will not be

subject to damage, such as under the center of the dash above

the transmission hump. Mark the position of the mounting holes,

drill two holes and mount the control box with the wire harness

coming out the bottom of the unit.

□ Mount the throttle control under the dash near the steering

column using plastic ties in a position where the harness

connectors on the throttle control will reach the OEM accelerator

connectors.

□ Route the following wires into the engine compartment through a

suitable OEM plug in the firewall. One location is the large wire

harness plug behind the park brake:

grey wire with a 3 pin black connector

grey wire with a 4 pin green connector

white wire with a plug connector

white wire with no connector

automatic transmission vehicles – blue wire with no connector

3.2 Connecting the In-cab Wiring

□ Unplug the OEM cable from the accelerator pedal and plug it into

the matching connector from the throttle control box. Plug the

cable from the throttle control into the matching connector on the

accelerator pedal.

□ Connect the two white interface connectors together.

□ Connect the red wire from the throttle controller to the red wire

from the interface cable.

□ Connect the ground wire from the throttle control to a good

ground under the dash.

□ Remove the connector from the park brake switch, connect it to

the piggyback connector on the black wire from the interface

connector and plug it back onto the park brake switch.

VMAC – Vehicle Mounted Air Compressors

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Fax: 1-250-740-3201

3.2.1 V900093 Power Connection (prior to 2008)

□ Locate the Mid-Bussed Electrical Center (MBEC) under the

instrument panel and left of the steering column (Figure 3.1).

Mid-Bussed Electrical Center

SEO Port

Figure 3.1

□ Remove the cover and locate the SEO port. Connect the power

and ground plug from the interface cable to the SEO port (Figure

3.2) and replace the cover.

If the connector in the SEO port already has a wire in

location “C”, you can splice the red wire into that wire

or locate an alternate power source, such as the hot

side of an ignition switch controlled fuse on the fuse

panel.

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Vmac V900103 Installation guide

Brand: Vmac

Model: V900103

Type: Installation guide

This manual is also suitable for

V900093

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Vmac V900103 Installation guide

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Vmac V900103 Installation guide

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